Method for forming molded fiber products with deckle-free windows

ABSTRACT

Apparatus and method for forming deckle-free windows or openings in molded fiber products such as cartons, trays and the like, said apparatus comprising an air distributor manifold box with jet tubes whereby a blast of air may be directed against a blockout patch to lift deckle therefrom. The manifold box is movable to a discharge position and in contact with a switch which is operable to open a solenoid valve in a fluid conduit which connects said manifold box to an air accumulator tank, the operation of said apparatus providing the method of removing deckle from the surface of block-out patches disposed on forming molds to form windows. The method includes removing deckle from the surface of block-out patches by an air jet and pressing the up-lifted deckle into surrounding fiber portions to reinforce said surrounding portions.

United States Patent WINDOWS [75} Inventor: Henry A. Lord, CapeElizabeth,

Maine [73] Assignee: Diamond International Corporation.

New York, NY.

[22] Filed: June 12, 1974 [21] Appl. No.: 481,851

Related US. Application Data [62] Division of Sen No. 264,190. June 19,1972, Pat. No.

[52] US. Cl. 162/195; 162/208; 162/227; 162/228; 162/286; 162/291 [51]Int. Cl. 021,] 3/00 [58] Field of Search 239/553, 562, 565, 566,239/569; 162/228, 227, 208, 195, 286, 387, 388, 391, 396, 399, 400;249/66 A [56] References Cited UNITED STATES PATENTS 2,320,789 6/1943Montague et al 162/195 2,760,412 8/1956 Lemieux 162/228 Lord 1 Dec. 2,1975 [5 METHOD FOR FORMING MOLDED FIBER 3.046.187 7/1962 Leitzel 162/228PRODUCTS WITH DECKLEJREE 3,567.575 3/1971 Emergy 1, 162/387 PrimaryErunziner-Robert L. Lindsay. Jr. Assistant E.raminerRichard V. FisherAttorney, Agent, or Firm-Karl W. Flocks [57] ABSTRACT Apparatus andmethod for forming deckle-free windows or openings in molded fiberproducts such as cartons, trays and the like. said apparatus comprisingan air distributor manifold box with jet tubes whereby a blast of airmay be directed against a block-out patch to lift deckle therefrom. Themanifold box is movable to a discharge position and in contact with aswitch which is operable to open a solenoid valve in a fluid conduitwhich connects said manifold box to an air accumulator tank, theoperation of said apparatus providing the method of removing deckle fromthe surface of block-out patches disposed on forming molds to formwindows. The method includes removing deckle from the surface ofblock-out patches by an air jet and pressing the up-lifted deckle intosurrounding fiber portions to reinforce said surrounding por- 4 Claims,6 Drawing Figures US. Patent me. 2, 1975 Sheet 1 of 2 3,923,594

US. Patent Dec. 2, 1975 Sheet 2 of2 3,923,594v

I l5 l9 all/Ill tm m m w nmmvamau METHOD FOR FORMING MOLDED FIBERPRODUCTS WITH DECKLE-FREE WINDOWS This is a division of application Ser.No. 264,190,

filed June 19, 1972, now US. Pat. No. 3,871,586.

BACKGROUND OF THE INVENTION 1. Field of the Invention The field of theinvention is believed to encompass art found in Class 162, subclasses227 and 286.

2. Description of the Prior Art In the production of molded fiberproducts it is frequently desirable to form one or more apertures orwindows therein, in particular in cartons or trays. The windows areformed by providing the forming molds with non-porous block-out patchesor blocks. Concomitant with the use of block-out patches there is abuild-up of undesirable fiber, known as deckle, around the edge of thewindows. The removal of this undesirable fiber or deckle has beenapproached in the past, for example, by the application of water sprayedin the area to remove the deckle. The use of water spray to removedeckle has not been altogether satisfactory in that:

A. stray fibers frequently remain around the edge of the windows,

B. thickness of pulp formation in the window area may be adverselythinned out,

C. pulp furnish in machine vat may be diluted, and

D. manufacturing time is undesirably extended.

Other approaches for removing deckle include the use of air as disclosedin US. Pat. No. 2,923,654 to Comstock. It is noted that Comstock usesair in the vac: uum forming die to remove deckle. The specific approachof Comstock complicates the die construction, die changing on themachine, and machine construction. Its practical use is for a very smallarea on a special purpose machine.

SUMMARY OF THE INVENTION The present invention relates to improvementsin an apparatus and a process for use in forming molded fiber productswith windows therein. In particular, it is an object of this inventionto provide an apparatus and method for forming molded fiber productswith decklefree openings or windows therein having edges with cleanlines.

It is also an object of this invention to form a molded fiber productwith windows therein having reinforced edges there around.

It is additionally an object of this invention to provide an apparatusand method for increasing the speed of manufacturing deckle-free windowsin molded fiber products.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation of theapparatus according to the present invention shown in use in conjunctionwith a molded fiber product molding machine;

FIG. 2 is a fragmentary view looking at the top of the forming mold justafter pulp has been applied thereto;

FIG. 3 is a sectional view taken along line 3 3 in FIG. 2;

FIG. 4 is a view similar to FIG. 3 showing portions of jet tubes rotated90 from the position in FIG. 1 for convenience;

FIG. 5 is a view similar to FIG. 4 showing a fragmentary portion of apressing mold applied against the uplifted deckle; and

FIG. 6 is a fragmentary top plan view of a molded fiber product preformwith deckle-free windows.

DETAILED DESCRIPTION OF THE APPARATUS ACCORDING TO THIS INVENTIONReferring now particularly to FIG. 1, the apparatus according to thepresent invention is shown in use in conjunction with a rotating moldedfiber product molding machine 10. The molding machine 10 comprises arotating wheel 12 which carries a plurality of forming molds 14, 14',etc. Each forming mold as shown is provided with a plurality ofgenerally flat, non-porous block-out patches 15 for the formation ofwindows. As shown, the rotating wheel 12 continuously moves each formingmold into a vat V of pulp slurry and thereafter adjacent an airdistributor manifold box 20, below a pressing mold 16 and finally to aconveying belt 18 upon which preforms may be taken to a drying oven, forexample.

The apparatus according to the present invention comprises the airdistributor manifold box 20 which is provided with a plurality of jetoutlet tubes 22 on one face thereof and a flexible hose 30 connected tothe opposite face thereof. As shown in FIG. 1, air distributor manifoldbox 20 is fixedly connected to support link 24 for pivotal movementabout pin 26. A microswitch mechanism 28 is fixedly disposed on themolding machine side of the support link 24. Flexible hose 30 isconnected to a high pressure air accumulator tank 34. A solenoidoperated valve 32 is disposed in the circuit of the flexible hose 30between air distributor manifold box 20 and high pressure airaccumulator tank 34. Upon movement of support link 24 from the phantomposition to the solid position and into contact with microswitch 28,which is electrically connected to the solenoid of valve 32, the valve32 will be opened to allow a burst of air to tank 34, through hose 30,into box 20 and out tubes 22.

On the upstream side of accumulator tank 34 compressed air is suppliedthereto by way of pipe 36 in which there is provided an air pressureregulator valve 38. Air, for example, may be supplied in pipe 36 at lbs.p.s.i. It is important that the diameter of pipe 36 be substantiallysmaller than that of discharge hose 30, so that the high pressure air isquickly dissipated to allow retraction of the air jet tubes withoutdelamination of pulp in the area of the windows that are formed. In thisconnection pipe 36 might conveniently have a diameter of Va inchcompared to a /4 inch diameter for hose 30. It is also noted that airtank 34 may be provided with an air pressure gauge 40 to determine thepressure therein.

METHOD AND OPERATION OF THE APPARATUS TO FORM DECKLE-FREE WINDOWS Inconjunction with the operation of the present invention the moldingwheel 12 of molding machine 10 is rotated in the counter-clockwisedirection as shown in FIG. 1 whereby each of the forming molds 14 areimmersed in the fiber Vat V and coated with a pulp slurry.

As the forming mold l4 emerges from the pulp vat the forming mold 14will be covered with a pulp slurry 19. The non-porous block-out patches15 on the mold 14 will have its edges surrounded by deckle 21. Asclearly seen in FIG. 3 forming mold 14 is lined with a screening wire 17upon which a plurality of spaced apart nonporous block-out patches 15are disposed to form windows in the molded product and deckle portions21 are superimposed over the edges of the patches 15.

As the forming mold 14 moves to a generally vertical position as shownin FIG. 1 support link 24 is moved from the position shown in phantom tothe solid line position in which air distributor manifold box extendsgenerally parallel to mold l4 and at which time support link 24 strikesmicroswitch mechanism 28 which opens solenoid operated valve 32 to allowa burst of air from accumulator tank 34 to pass through flexible hose 30into air distributor box 20 and discharge through jet tubes 22 andagainst block-out patches 15. Each jet tube 22 is directed against thecenter of a patch 15 whereby a blast of air A sweeps across the face ofeach patch 15 to lift the deckle 21 off the patch and into upstandingposition as shown in FIG. 4.

After the deckle 21 around each patch 15 is blasted into the upstandingposition support link 24 is backed away to the phantom position shown inFIG. 1 and out of engagement with microswitch 28 whereby the solenoidoperated valve 32 closes to permit build-up of air pressure inaccumulator tank 34 for the next cycle. At the same time mold 14continues in the counterclockwise direction to a position beneath apressure mold 16, such as a wet press head, for example, which islowered in mating relationship with forming mold l4 and therebycompressing the upstanding deckle 21 against the pulp portions 19 asshown in FIG. 5.

Upon this engagement of molds 14 and 16, the fiber product preform 23 isformed with deckle-free windows having clean smooth lines andsurrounding portions 19 with reinforced pressed-together portions 21surrounding the windows as illustrated in FIG. 6.

It will be obvious to those skilled in the art that various changes maybe made without departing from the scope of the invention and theinvention is not to be considered limited to what is shown in thedrawings and described in the specification.

I claim:

1. The method of forming deckle-free windows in molded fiber productscomprising the steps of:

a. applying pulp slurry on a forming mold provided with one or moreblock-out patches for forming one or more windows in the finishedproduct;

b. moving said forming mold with pulp slurry applied thereon to a deckleremoving position whereby deckle formed on said one or more block-outpatches may be removed therefrom; and

0. moving an air distributor manifold box with one or more jet tubesinto very close proximity to said block-out patches and discharging highpressure air through each of said jet tubes against each of saidblock-out patches thereby blasting deckle off the top of each block-outpatch, said high pressure air being discharged through said jet tubeswith each of said jet tubes directed over the center of a blockout patchassociated therewith whereby the air emitting from each jet tube strikesthe top of the block-out patch and moves radially outwardly thereacrossto sweep the deckle therefrom and over surrounding pulp portions clearof the blockout patch.

2. The method as recited in claim 1 wherein said pulp slurry is appliedto said forming mold as it is moved.

3. The method as recited in claim 2 wherein said forming mold is movedin a continuous motion and said air distributor manifold box is movedalternately to and from discharging positions thereof to allow forpressure build-up in an accumulator therefor.

4. The method as recited in claim 3 in combination with further steps ofmoving said forming mold to a pressing position and forceably pressingsaid blasted deckle down against and into pulp portions clear of the

1. THE METHOD OF FORMING DECKLE-FREE WINDOWS IN MOLDED FIBER PRODUCTSCOMPRISING THE STEPS OF: A. APPLYING PULP SLURRY ON A FORMING MOLDPROVIDED WITH ONE OR MORE BLOCK-OUT PATCHES FOR FORMING ONE OR MOREWINDOWS IN THE FINISHED PRODUCT; B. MOVING SAID FORMING MOLD WITH PULPSLURRY APPLIED THEREON TO A DECKEL REMOVING POSITION WHEREBY DECKLEFORMED ON SAID ONE OR MORE BLOCK-OUT PATCHES MAY BE REMOVED THEREFROM;AND C. REMOVING AN AIR DISTRIBUTOR MANIFOLD BOX WITH ONE OR MORE JETTUBES INTO VERY CLOSE PROXIMITY TO SAID BLOCK-OUT PATCHES ANDDISCHARGING HIGH PRESSURE AIR THROUGH EACH OF SAID LET TUBES AGAINSTEACH OF SAID BLOCK-OUT PATCHES THEREBY BLASTING DECKLE OFF THE TOP OFEACH BLOCK-OUT PATCH, SAID HIGH PRESSURE AIR BEING DISCHARGED THROUGHSAID JET TUBES WITH EACH OF SAID JET TUBES DIRECTED OVER THE CENTER OF ABLOCK-OUT PATCH ASSOCIATED THEREWITH WHEREBY THE AIR EMITTING FROM EACHJET TUBE STRIKES THE TOP OF THE BLOCK-OUT PATCH AND MOVES RADIALLYOUTWARDLY THEREACROSS TO SWEEP THE DECKLE THEREFROM AND OVER SURROUNDINGPULP PORTIONS CLEAR OF THE BLOCK-OUT PATCH.
 1. The method of formingdeckle-free windows in molded fiber products comprising the steps of: a.applying pulp slurry on a forming mold provided with one or moreblock-out patches for forming one or more windows in the finishedproduct; b. moving said forming mold with pulp slurry applied thereon toa deckle removing position whereby deckle formed on said one or moreblock-out patches may be removed therefrom; and c. moving an airdistributor manifold box with one or more jet tubes into very closeproximity to said block-out patches and discharging high pressure airthrough each of said jet tubes against each of said block-out patchesthereby blasting deckle off the top of each block-out patch, said highpressure air being discharged through said jet tubes with each of saidjet tubes directed over the center of a block-out patch associatedtherewith whereby the air emitting from each jet tube strikes the top ofthe block-out patch and moves radially outwardly thereacross to sweepthe deckle therefrom and over surrounding pulp portions clear of theblock-out patch.
 2. The method as recited in claim 1 wherein said pulpslurry is applied to said forming mold as it is moved.
 3. The method asrecited in claim 2 wherein said forming mold is moved in a continuousmotion and said air distributor manifold box is moved alternately to andfrom discharging positions thereof to allow for pressure build-up in anaccumulator therefor.
 4. The method as recited in claim 3 in combinationwith further steps of moving said forming mold to a pressing positionand forceably pressing said blasted deckle down against and into pulpportions clear of the block-out patch.